scholarly journals Novel Damage Calibration Test Based on Cross-Wedge Rolling

2021 ◽  
Author(s):  
Zbigniew Pater ◽  
Janusz Tomczak ◽  
Tomasz Bulzak ◽  
Patrycja Walczuk-Gągała
Keyword(s):  
Cross Wedge Rolling ◽  
Calibration Test

scholarly journals Determination of the Critical Value of Material Damage in a Cross Wedge Rolling Test

Materials ◽  
2021 ◽  
Vol 14 (7) ◽  
pp. 1586
Author(s):  
Zbigniew Pater ◽  
Andrzej Gontarz ◽  
Janusz Tomczak ◽  
Tomasz Bulzak ◽  
Łukasz Wójcik
Keyword(s):  
Test Piece ◽  
Finite Element Method Simulation ◽  
Fracture Initiation ◽  
Critical Value ◽  
Material Damage ◽  
Cross Wedge Rolling ◽  
Calibration Test ◽  
Axial Crack ◽  
Material Fracture ◽  
Critical Damage

This study investigates the problem of material fracture in cross wedge rolling (CWR). It was found that this problem could be analysed by means of well-known phenomenological criteria of fracture that are implemented in commercial FEM (Finite Element Method) simulation programs for forming processes. The accuracy of predicting material fracture depends on the critical damage value that is determined by calibration tests in which the modelled and real stresses must be in good agreement. To improve this accuracy, a new calibration test is proposed. The test is based on the CWR process. Owing to the shape of the tools and test piece used in CWR, the forming conditions in this process deteriorate with the distance from the centre of the test piece, which at a certain moment leads to fracture initiation. Knowing the location of axial crack initiation in the specimen, it is possible to determine the critical value of material damage via numerical simulation. The new calibration test is used to determine the critical damage of 42CrMo4 steel subjected to forming in the temperature range of 900–1100 °C. In addition, 12 criteria of ductile fracture are employed in the study. The results show that the critical damage significantly increases with the temperature.

Analysis on Temperature Field of Work-Piece during Cross Wedge Rolling

2011 ◽  
Vol 230-232 ◽  
pp. 352-356
Author(s):  
Wen Ke Liu ◽  
Kang Sheng Zhang ◽  
Zheng Huan Hu
Keyword(s):  
Finite Element ◽  
Temperature Field ◽  
Metal Flow ◽  
Work Piece ◽  
Contact Deformation ◽  
Cross Wedge Rolling ◽  
Forming Process ◽  
Rigid Plastic ◽  
Finite Element Software ◽  
Deform 3D

Based on the rigid-plastic deformation finite element method and the heat transfer theories, the forming process of cross wedge rolling was simulated with the finite element software DEFORM-3D. The temperature field of the rolled piece during the forming process was analyzed. The results show that the temperature gradient in the outer of the work-piece is sometimes very large and temperature near the contact deformation zone is the lowest while temperature near the center of the rolled-piece keeps relatively stable and even rises slightly. Research results provide a basis for further study on metal flow and accurate shaping of work-piece during cross wedge rolling.

Stress distributions during the cross-wedge rolling of composite 42CrMo/Q235 laminated shafts

2015 ◽  
Vol 83 (1-4) ◽  
pp. 145-155 ◽  
Author(s):  
W. F. Peng ◽  
J. H. Zhang ◽  
G. X. Huang ◽  
W. P. Liu ◽  
X. D. Shu ◽  
...  
Keyword(s):  
Stress Distributions ◽  
Cross Wedge Rolling ◽  
The Cross

The Strain Analysis at the Broadening Stage of the Hollow Railway Axle by Multi-Wedge Cross Wedge Rolling

2014 ◽  
Vol 494-495 ◽  
pp. 457-460 ◽  
Author(s):  
Bin Hu ◽  
Xue Dao Shu ◽  
Peng Hui Yu ◽  
Wen Fei Peng
Keyword(s):  
Production Efficiency ◽  
Strain Analysis ◽  
Cross Wedge Rolling ◽  
Forming Process ◽  
Element Analysis ◽  
Forming Mechanism ◽  
Railway Axle ◽  
The Finite Element Analysis ◽  
Scientific Significance ◽  
Deform 3D

The paper is based on the newest hollow railway axle, which utilizes the Pro/E designed multi-wedge cross wedge rolling (MCWR) model, utilizes the finite element analysis software DEFORM-3D to complete the numerical simulation about the whole stage of the hollow railway axle forming process, and analyzes the strain rule at the broadening stage of the hollow railway axle, especially conducts a detailed research on forming character into the strain rule at the multi-wedge transition stage, and finally gets the strain forming mechanism of the hollow railway axle at the broadening stage. The result of the research on the strain rule poses great scientific significance on enhancing the product quality and the production efficiency of the hollow railway axle, and improving the theory of multi-wedge cross wedge rolling.

The Calculation Method of Accurate Shaping Curve of Inside Right-Angle Step in Cross Wedge Rolling

2010 ◽  
Vol 37-38 ◽  
pp. 1416-1420 ◽  
Author(s):  
Ran Zhao ◽  
Kang Sheng Zhang ◽  
Zheng Huan Hu
Keyword(s):  
Numerical Simulation ◽  
Mathematical Models ◽  
Contact Zone ◽  
Calculation Method ◽  
Cross Wedge Rolling ◽  
Forming Process

Deep study on Inside Right-angle Step (IRS) forming process was conducted to improve the precision of its (IRS) forming. According to its actual forming process, the zone, or the undeformed zone, was looked as semi-spiral declined cone and excluded the contact zone. A new algorithm was developed for calculating the size of the undeformed zone. More simple mathematical models and expressions weredeveloped for solving the shaping curve. The model was verified in terms of its simplicity and correctness based on the numerical simulation.

scholarly journals The process parameters effect of ovality in cross wedge rolling for hollow valve without mandril

2016 ◽  
Vol 80 ◽  
pp. 13003 ◽  
Author(s):  
Hongchao Ji ◽  
Jinping Liu ◽  
Baoyu Wang ◽  
Jianguo Lin ◽  
Xuefeng Tang
Keyword(s):  
Process Parameters ◽  
Cross Wedge Rolling

FEM Simulation Analysis of Cross Wedge Rolling Process

2011 ◽  
Vol 381 ◽  
pp. 72-75
Author(s):  
Bin Li
Keyword(s):  
Simulation Analysis ◽  
Three Dimensional ◽  
Fem Simulation ◽  
Rolling Process ◽  
Stress Distributions ◽  
Cross Wedge Rolling ◽  
Forming Process ◽  
Pressure Distributions ◽  
Metal Forming Process ◽  
Rolling Load

This paper investigates the interfacial slip between the forming tool and workpiece in a relatively new metal forming process, cross-wedge rolling. Based on the finite elements method, three-dimensional mechanical model of cross wedge rolling process has been developed. Examples of numerical simulation for strain, stress distributions and rolling load components have been included. The main advantages of the finite element method are: the capability of obtaining detailed solutions of the mechanics in a deforming body, namely, stresses, shapes, strains or contact pressure distributions; and the computer codes, can be used for a large variety of problems by simply changing the input data.

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